CMC ARC SEGMENT INTERFACE GAP FLOW BLOCKER
A gas turbine engine includes a plurality of ceramic matrix composite (CMC) arc segments arranged in a row. There is a leak path through which gas from the engine core gas path can bypass an axial section of the engine core gas path. A CMC strip is disposed at the inter-segment interface between CMC arc segments to block the leak path and reduce leakage of the gas.
A gas turbine engine typically includes a fan section, a compressor section, a combustor section and a turbine section. Air entering the compressor section is compressed and delivered into the combustion section where it is mixed with fuel and ignited to generate a high-pressure and temperature exhaust gas flow. The high-pressure and temperature exhaust gas flow expands through the turbine section to drive the compressor and the fan section. The compressor section may include low and high pressure compressors, and the turbine section may also include low and high pressure turbines.
Airfoils and other components in the turbine section are typically formed of a superalloy and may include thermal barrier coatings to extend temperature capability and lifetime. Ceramic matrix composite (“CMC”) materials are also being considered for these components. Among other attractive properties, CMCs have high temperature resistance. Despite this attribute, however, there are unique challenges to implementing CMCs.
SUMMARYA gas turbine engine according to an example of the present disclosure includes a full hoop support ring adjacent an engine core gas path and a plurality of ceramic matrix composite (CMC) arc segments arranged in a row between the full hoop support ring and the engine core gas path such that the CMC arc segments bound a portion of the engine core gas path. Each of the CMC arc segments has a core gas path side, an opposed non-core gas path side, an axially forward-facing leading side, and axially aft-facing trailing side, a first circumferential mate face, and a second circumferential mate face. The first circumferential mate face mates at an interface with the second circumferential mate face of an adjacent one of the CMC arc segments in the row. The non-core gas path side and the full hoop support ring radially bound there between an axially-extending passage. There is a leak path through which gas from the engine core gas path can bypass an axial section of the engine core gas path. The leak path extends from an upstream high pressure zone of the engine core gas path, then through an upstream location of the interface into the axially-extending passage, then through the axially-extending passage, then through a downstream location of the interface, and then into a downstream low pressure zone of the engine core gas path. A CMC strip is disposed at the interface and blocks the leak path to reduce leakage of the gas through the leak path.
In a further embodiment of any of In a further embodiment of any of the foregoing embodiments, the CMC strip includes fibers disposed in a ceramic matrix, and the fibers have less than 500 filaments per fiber.
In a further embodiment of any of the foregoing embodiments, the CMC strip includes, by volume, 30% to 70% of ceramic fibers and 70% to 30% of ceramic matrix.
In a further embodiment of any of the foregoing embodiments, the ceramic fibers are silicon carbide and the ceramic matrix is silicon carbide.
In a further embodiment of any of the foregoing embodiments, the first circumferential mate face has a first groove, the second circumferential mate face has a second groove that faces the first groove such that the first groove and the second groove form a slot, and the CMC strip is disposed in the slot.
In a further embodiment of any of the foregoing embodiments, the slot includes a coating.
In a further embodiment of any of the foregoing embodiments, the coating is a silicon-containing coating.
In a further embodiment of any of the foregoing embodiments, the first circumferential mate face has a first groove, the second circumferential mate face has a second groove that faces the first groove such that the first groove and the second groove form a slot, the first circumferential mate face has a land that interrupts the first groove, the CMC strip is disposed in the slot, and the CMC strip includes a notch that fits over the land.
In a further embodiment of any of the foregoing embodiments, the CMC arc segments are uncooled.
In a further embodiment of any of the foregoing embodiments, the CMC arc segments are airfoil fairings.
A further embodiment of any of the foregoing embodiments includes a compressor section, a combustor in fluid communication with the compressor section, and a turbine section in fluid communication with the combustor, and the CMC arc segments are in the turbine section.
A gas turbine engine according to an example of the present disclosure includes a full hoop support ring adjacent an engine core gas path and a plurality of ceramic matrix composite (CMC) arc segments arranged in a row between the full hoop support ring and the engine core gas path such that the CMC arc segments bound a portion of the engine core gas path. Each of the CMC arc segments has a core gas path side, an opposed non-core gas path side, an axially forward-facing leading side, and axially aft-facing trailing side, a first circumferential mate face, and a second circumferential mate face. The first circumferential mate face mates at an interface with the second circumferential mate face of an adjacent one of the CMC arc segments in the row. The first circumferential mate face has a first groove and the second circumferential mate face has a second groove that faces the first groove such that the first groove and the second groove form a slot. The non-core gas path side and the full hoop support ring radially bound there between an axially-extending passage. There is a leak path through which gas from the engine core gas path can bypass an axial section of the engine core gas path. The leak path extends from an upstream high pressure zone of the engine core gas path, then through an upstream location of the interface into the axially-extending passage, then through the axially-extending passage, then through a downstream location of the interface, and then into a downstream low pressure zone of the engine core gas path. There is a CMC member retained in the slot.
In a further embodiment of any of the foregoing embodiments, the CMC member includes fibers disposed in a ceramic matrix, and the fibers have less than 500 filaments per fiber.
In a further embodiment of any of the foregoing embodiments, the CMC member includes, by volume, 30% to 70% of ceramic fibers and 70% to 30% of ceramic matrix.
In a further embodiment of any of the foregoing embodiments, the ceramic fibers are silicon carbide and the ceramic matrix is silicon carbide.
In a further embodiment of any of the foregoing embodiments, the slot includes a coating.
In a further embodiment of any of the foregoing embodiments, the coating is a silicon-containing coating.
In a further embodiment of any of the foregoing embodiments, the CMC arc segments are airfoil fairings.
In a further embodiment of any of the foregoing embodiments, the CMC member is a CMC strip.
The present disclosure may include any one or more of the individual features disclosed above and/or below alone or in any combination thereof.
The various features and advantages of the present disclosure will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows.
The exemplary engine 20 generally includes a low speed spool 30 and a high speed spool 32 mounted for rotation about an engine central longitudinal axis A relative to an engine static structure 36 via several bearing systems 38. It should be understood that various bearing systems 38 at various locations may alternatively or additionally be provided, and the location of bearing systems 38 may be varied as appropriate to the application.
The low speed spool 30 generally includes an inner shaft 40 that interconnects, a first (or low) pressure compressor 44 and a first (or low) pressure turbine 46. The inner shaft 40 is connected to the fan 42 through a speed change mechanism, which in exemplary gas turbine engine 20 is illustrated as a geared architecture 48 to drive a fan 42 at a lower speed than the low speed spool 30. The high speed spool 32 includes an outer shaft 50 that interconnects a second (or high) pressure compressor 52 and a second (or high) pressure turbine 54. A combustor 56 is arranged in the exemplary gas turbine 20 between the high pressure compressor 52 and the high pressure turbine 54. A mid-turbine frame 57 of the engine static structure 36 may be arranged generally between the high pressure turbine 54 and the low pressure turbine 46. The mid-turbine frame 57 further supports bearing systems 38 in the turbine section 28. The inner shaft 40 and the outer shaft 50 are concentric and rotate via bearing systems 38 about the engine central longitudinal axis A which is collinear with their longitudinal axes.
The core airflow is compressed by the low pressure compressor 44 then the high pressure compressor 52, mixed and burned with fuel in the combustor 56, then expanded through the high pressure turbine 54 and low pressure turbine 46. The mid-turbine frame 57 includes airfoils 59 which are in the core gas path C. The turbines 46, 54 rotationally drive the respective low speed spool 30 and high speed spool 32 in response to the expansion. It will be appreciated that each of the positions of the fan section 22, compressor section 24, combustor section 26, turbine section 28, and fan drive gear system 48 may be varied. For example, gear system 48 may be located aft of the low pressure compressor, or aft of the combustor section 26 or even aft of turbine section 28, and fan 42 may be positioned forward or aft of the location of gear system 48.
The engine 20 in one example is a high-bypass geared aircraft engine. In a further example, the engine 20 bypass ratio is greater than about six (6), with an example embodiment being greater than about ten (10), and can be less than or equal to about 18.0, or more narrowly can be less than or equal to 16.0. The geared architecture 48 is an epicyclic gear train, such as a planetary gear system or other gear system, with a gear reduction ratio of greater than about 2.3. The gear reduction ratio may be less than or equal to 4.0. The low pressure turbine 46 has a pressure ratio that is greater than about five. The low pressure turbine pressure ratio can be less than or equal to 13.0, or more narrowly less than or equal to 12.0. In one disclosed embodiment, the engine 20 bypass ratio is greater than about ten (10:1), the fan diameter is significantly larger than that of the low pressure compressor 44, and the low pressure turbine 46 has a pressure ratio that is greater than about five 5:1. Low pressure turbine 46 pressure ratio is pressure measured prior to an inlet of low pressure turbine 46 as related to the pressure at the outlet of the low pressure turbine 46 prior to an exhaust nozzle. The geared architecture 48 may be an epicycle gear train, such as a planetary gear system or other gear system, with a gear reduction ratio of greater than about 2.3:1 and less than about 5:1. It should be understood, however, that the above parameters are only exemplary of one embodiment of a geared architecture engine and that the present invention is applicable to other gas turbine engines including direct drive turbofans.
A significant amount of thrust is provided by the bypass flow B due to the high bypass ratio. The fan section 22 of the engine 20 is designed for a particular flight condition—typically cruise at about 0.8 Mach and about 35,000 feet (10,668 meters). The flight condition of 0.8 Mach and 35,000 ft (10,668 meters), with the engine at its best fuel consumption—also known as “bucket cruise Thrust Specific Fuel Consumption (′TSFC)”—is the industry standard parameter of lbm of fuel being burned divided by lbf of thrust the engine produces at that minimum point. The engine parameters described above and those in this paragraph are measured at this condition unless otherwise specified. “Low fan pressure ratio” is the pressure ratio across the fan blade alone, without a Fan Exit Guide Vane (“FEGV”) system. The low fan pressure ratio as disclosed herein according to one non-limiting embodiment is less than about 1.45, or more narrowly greater than or equal to 1.25. “Low corrected fan tip speed” is the actual fan tip speed in ft/sec divided by an industry standard temperature correction of [(Tram ° R)/(518.7° R)]0.5. The “Low corrected fan tip speed” as disclosed herein according to one non-limiting embodiment is less than about 1150.0 ft/second (350.5 meters/second), and can be greater than or equal to 1000.0 ft/second (304.8 meters/second).
To demonstrate an example implementation in accordance with this disclosure,
In the illustrated example, the CMC arc segments 62 are CMC vane arc segments and are supported radially between two of the full hoop support rings 61 (radially inner and outer). The CMC vane arc segments are singlets (single airfoil) in the example shown, but they could alternatively be doublets (two airfoils) or greater (multiplets). It is to be further understood that that the examples herein are not limited to vanes or to the turbine section 28, and the examples may also be applicable to other types of CMC arc segments in the engine 20, such as but not limited to, blade outer air seals, turbine blades, and liners.
Referring also to
In this example, the first platform 64 of the CMC vane arc segment is a radially outer platform and the second platform 66 is a radially inner platform. It is also contemplated, however, that in modified examples the CMC vane arc segment could alternatively have the first platform 64 as a single platform, with no second platform 66, in which case the single platform may be at either the radially inner or outer end of the airfoil section 68. Terms such as “inner” and “outer” used herein refer to location with respect to the central engine axis A, i.e., radially inner or radially outer. Moreover, the terminology “first” and “second” used herein is to differentiate that there are two architecturally distinct components or features. It is to be further understood that the terms “first” and “second” are interchangeable in that a first component or feature could alternatively be termed as the second component or feature, and vice versa.
Each of the platforms 64/66 defines a core gas path side 70a, an opposed non-core gas path side 70b, an axially forward-facing leading side 70c, and axially aft-facing trailing side 70d, a first circumferential mate face 70e, and a second circumferential mate face 70f. A CMC arc segment 62 other than a vane may have analogous sides on the main body of the component rather than a platform. Referring to
The CMC vane arc segments are continuous in that the platforms 64/66 and airfoil section 68 constitute a single, uninterrupted body. In the example in
During operation of the engine hot combustion gases flow through the core gas path C and axially across the airfoil section 68. In general, there is a pressure differential between upstream and downstream locations in the core gas path in the turbine section 28. For instance, referring to
In this regard, there is a CMC member 76 disposed at the interface 71 that blocks the leak path 74 to reduce leakage of the combustion gas flow through the leak path 74. As an example, leakage may be measured or estimated in units of pound mass per second (lbm/s). The CMC member 76 may generally be of the same composition as the CMC of the CMC arc segment 62, such as a SiC/SiC composite.
Referring to
The CMC member 76 serves as a physical barrier to flow, as opposed to a seal per se. A seal necessarily provides a tight fit against a mating surface and the tight fit substantially prevents flow between the seal and the surface. For example, feather seals that are sometimes used in mate face gaps are pressurized (by compressor bleed air) against a mating wall and are highly compliant in order to closely conform and seal against the wall. The CMC member 76 may bear against the sides of the grooves 78 and in that sense may provide modest physical sealing, but it does not necessarily tightly seal as a feather seal does.
The CMC member 76 is adapted to facilitate physical blocking of the gas flow through the leak path 74. In this regard, the CMC member 76 is formed to have smooth surfaces and low porosity. For example, the CMC member 76 is formed with ceramic fibers of relatively low filament count, such as less than 500 filaments per fiber or less than 250 filaments per fiber. The configuration of the fibers manifests as a surface roughness on the CMC member 76 in that there are undulations over the fibers because they do not lay completely flat. The low filament count produces a finer filament architecture that, in comparison to higher filament counts, reduces the surface roughness and thus reduces the size of small gaps between the sides of the grooves 78 and the CMC member 76. Additionally, a low filament count reduces the size of intra-fiber gaps between the filaments that may otherwise provide leak paths through the CMC member 76. A high fiber packing content may also be used in the CMC member 76 to reduce inter-fiber gaps. For example, the CMC member 76 may include, by volume, 30% to 70% of ceramic fibers and 70% to 30% of ceramic matrix. In one further example, the CMC member 76 includes 40% to 60% of ceramic fibers and 60% to 40% of ceramic matrix
The fabrication of the CMC member 76 may also be selected to enhance blocking of the flow. For example, a process such as chemical vapor infiltration used to deposit the matrix material may result in a relatively high porosity. In some instances this porosity may still provide acceptable flow-blocking. However, processes such as melt infiltration or polymer infiltration and pyrolysis provide lower porosities that may in turn provide better flow-blocking. In general, the bulk porosity, by volume percentage, of the CMC member 76 is 25% or less.
The fiber architecture of the fibers of the CMC member 76 may be a 3-D weave, a 2-D weave, 2-D/3-D braids/knits, unidirectional, 2-D/3-D laminates/preformed structures, or combinations of these. In some cases, the fiber architecture may also be selected to enhance the ability of the CMC member 76 to block flow. For example, a 3-D woven architecture, in comparison to a 2-D architecture, may provide greater compliance that enables the CMC member 76 to better conform to the sides of the grooves 78, as well as a smoother surface. Example 3-D architectures include 3-D weave, layer-to-layer, through-thickness, or orthogonal angle interlocking.
As also shown in the example in
Although a combination of features is shown in the illustrated examples, not all of them need to be combined to realize the benefits of various embodiments of this disclosure. In other words, a system designed according to an embodiment of this disclosure will not necessarily include all of the features shown in any one of the Figures or all of the portions schematically shown in the Figures. Moreover, selected features of one example embodiment may be combined with selected features of other example embodiments.
The preceding description is exemplary rather than limiting in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from this disclosure. The scope of legal protection given to this disclosure can only be determined by studying the following claims.
Claims
1. A gas turbine engine comprising:
- a full hoop support ring adjacent an engine core gas path;
- a plurality of ceramic matrix composite (CMC) arc segments arranged in a row between the full hoop support ring and the engine core gas path such that the CMC arc segments bound a portion of the engine core gas path, each of the CMC arc segments having a core gas path side, an opposed non-core gas path side, an axially forward-facing leading side, and axially aft-facing trailing side, a first circumferential mate face, and a second circumferential mate face, the first circumferential mate face mating at an interface with the second circumferential mate face of an adjacent one of the CMC arc segments in the row, the first circumferential mate face having a first groove, the second circumferential mate face having a second groove that faces the first groove such that the first groove and the second groove form a slot, the slot including a coating of elemental silicon or silicon-molybdenum, the non-core gas path side and the full hoop support ring radially bounding there between an axially-extending passage;
- a leak path through which gas from the engine core gas path can bypass an axial section of the engine core gas path, the leak path extending from an upstream high pressure zone of the engine core gas path, then through an upstream location of the interface into the axially-extending passage, then through the axially-extending passage, then through a downstream location of the interface, and then into a downstream low pressure zone of the engine core gas path; and
- a CMC strip disposed in the slot and bearing against the coating, the CMC strip blocking the leak path to reduce leakage of the gas through the leak path.
2. The gas turbine engine as recited in claim 1, wherein the CMC strip includes fibers disposed in a ceramic matrix, and the fibers have less than 500 filaments per fiber.
3. The gas turbine engine as recited in claim 1, wherein the CMC strip includes, by volume, 30% to 70% of ceramic fibers and 70% to 30% of ceramic matrix.
4. The gas turbine engine as recited in claim 3, wherein the ceramic fibers are silicon carbide and the ceramic matrix is silicon carbide.
5. (canceled)
6. (canceled)
7. (canceled)
8. The gas turbine engine as recited in claim 1, wherein the first circumferential mate face has a land that interrupts the first groove, and the CMC strip includes a notch that fits over the land.
9. The gas turbine engine as recited in claim 1, wherein the CMC arc segments are uncooled.
10. The gas turbine engine as recited in claim 1, wherein the CMC arc segments are airfoil fairings.
11. The gas turbine engine as recited in claim 1, further comprising:
- a compressor section;
- a combustor in fluid communication with the compressor section; and
- a turbine section in fluid communication with the combustor, and the CMC arc segments are in the turbine section.
12. A gas turbine engine comprising:
- a full hoop support ring adjacent an engine core gas path;
- a plurality of ceramic matrix composite (CMC) arc segments arranged in a row between the full hoop support ring and the engine core gas path such that the CMC arc segments bound a portion of the engine core gas path, each of the CMC arc segments having a core gas path side, an opposed non-core gas path side, an axially forward-facing leading side, and axially aft-facing trailing side, a first circumferential mate face, and a second circumferential mate face, the first circumferential mate face mating at an interface with the second circumferential mate face of an adjacent one of the CMC arc segments in the row, the first circumferential mate face having a first groove and the second circumferential mate face having a second groove facing the first groove such that the first groove and the second groove form a slot, the slot including a coating of elemental silicon or silicon-molybdenum, the non-core gas path side and the full hoop support ring radially bounding there between an axially-extending passage;
- a leak path through which gas from the engine core gas path can bypass an axial section of the engine core gas path, the leak path extending from an upstream high pressure zone of the engine core gas path, then through an upstream location of the interface into the axially-extending passage, then through the axially-extending passage, then through a downstream location of the interface, and then into a downstream low pressure zone of the engine core gas path; and
- a CMC member retained in the slot and bearing against the coating.
13. The gas turbine engine as recited in claim 12, wherein the CMC member includes fibers disposed in a ceramic matrix, and the fibers have less than 500 filaments per fiber.
14. The gas turbine engine as recited in claim 12, wherein the CMC member includes, by volume, 30% to 70% of ceramic fibers and 70% to 30% of ceramic matrix.
15. The gas turbine engine as recited in claim 14, wherein the ceramic fibers are silicon carbide and the ceramic matrix is silicon carbide.
16. (canceled)
17. (canceled)
18. The gas turbine engine as recited in claim 12, wherein the CMC arc segments are airfoil fairings.
19. The gas turbine engine as recited in claim 12, wherein the CMC member is a CMC strip.
20. The gas turbine engine as recited in claim 1, wherein the coating is the elemental silicon.
21. The gas turbine engine as recited in claim 1, wherein the coating is the silicon-molybdenum.
Type: Application
Filed: May 13, 2022
Publication Date: Nov 16, 2023
Inventors: Robert A. White, III (Meriden, CT), Andrew Joseph Lazur (La Jolla, CA)
Application Number: 17/744,560